US20140290043A1 - Continuously formed annular laminated article and method for its manufacture - Google Patents
Continuously formed annular laminated article and method for its manufacture Download PDFInfo
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- US20140290043A1 US20140290043A1 US14/304,417 US201414304417A US2014290043A1 US 20140290043 A1 US20140290043 A1 US 20140290043A1 US 201414304417 A US201414304417 A US 201414304417A US 2014290043 A1 US2014290043 A1 US 2014290043A1
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- strip
- carousel
- pole pieces
- die assembly
- body segments
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- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title abstract description 13
- 238000009751 slip forming Methods 0.000 title description 2
- 238000004804 winding Methods 0.000 claims abstract description 23
- 238000003475 lamination Methods 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 abstract description 51
- 230000000750 progressive effect Effects 0.000 abstract description 12
- 239000002699 waste material Substances 0.000 abstract description 11
- 241000761557 Lamina Species 0.000 description 22
- 239000010410 layer Substances 0.000 description 22
- 238000000429 assembly Methods 0.000 description 9
- 230000000712 assembly Effects 0.000 description 9
- 230000037361 pathway Effects 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 229910000976 Electrical steel Inorganic materials 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 1
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- 239000002356 single layer Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
- H02K1/148—Sectional cores
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P80/00—Climate change mitigation technologies for sector-wide applications
- Y02P80/30—Reducing waste in manufacturing processes; Calculations of released waste quantities
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49075—Electromagnet, transformer or inductor including permanent magnet or core
- Y10T29/49078—Laminated
Definitions
- the present invention relates to progressive die assemblies that are used to manufacture relatively large diameter annular components, such as stator cores for electric motors.
- annular laminated parts such as stator cores
- stator cores in a manner in which individual annular laminations are stamped from a strip of steel stock material by a progressive die apparatus and are stacked and interlocked to form the part.
- each annular lamination is formed as a single piece, the width of the steel strip needs to be at least as large as the outer diameter of the lamination.
- a relatively large amount of the steel material is wasted when manufacturing annular laminated parts via known processes, for example, the material between adjacent laminations and within the interior of each lamination.
- a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations.
- the pole pieces, having protruding end portions, are loaded into a rotary carousel.
- a second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces.
- the continuous strip As the continuous strip is formed, it is wound about the rotary carousel with progressive pivoting of the body segments about the hinge portions to capture the protruding ends of the pole pieces within the recesses, with continued winding of the strip in a helical fashion around the rotary carousel continuing until a desired height is reached that is substantially equivalent to the height of the pole pieces.
- the strip is then cut, and the resulting annular part is welded at one or more locations to secure the components together.
- the present disclosure provides a method of forming an annular article, including the steps of: forming a plurality of pole pieces by forming, stacking, and interlocking a plurality of individual laminations in a first die assembly; loading the plurality of pole pieces onto a rotary carousel; forming a continuous strip in a second die assembly, the continuous strip including a plurality of body segments separated by gaps, the body segments connected via hinge portions; and rotating the carousel with concurrent winding of the strip around the carousel to progressively capture distal ends of the pole pieces within the gaps by pivoting the body segments about the hinge portions.
- the present disclosure provides an annular laminated article, including an annular core portion including a plurality of body segments connected by hinge portions; and a plurality of pole pieces separate from the core portion, each pole piece including an end portion captured between an adjacent pair of body segments.
- FIG. 1 is a perspective view of an annular laminated article according to an exemplary embodiment, the article including a core and multiple pole pieces;
- FIG. 2 is a perspective view of an exemplary pole piece of the annular laminated article of FIG. 1 ;
- FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 1 showing the interlocking between individual laminations of the pole piece;
- FIG. 4 is a fragmentary view of a portion of the core of FIG. 1 ;
- FIG. 5 is a fragmentary view of another portion of the core of FIG. 1 ;
- FIG. 6 is a strip layout of a first die assembly according to the present disclosure.
- FIG. 7 is an elevational, partially sectioned view of the first die assembly, showing the lower die assembly, the upper die assembly, punch sets, choke cavities, and a stock material feeder for feeding a strip of stock material into the die assembly;
- FIG. 8 is a strip layout of a second die assembly according to the present disclosure, also showing a rotary carousel configuration including the pole pieces of FIG. 1 , about which the strip formed by the second die assembly is wound upon rotation of the rotary carousel assembly;
- FIG. 9 is a fragmentary view showing the progressive reception of pole pieces into the gaps of the body segments of the strip of FIG. 8 ;
- FIG. 10 is an elevational, partially sectioned view of the second die assembly, showing the lower die assembly, the upper die assembly, punch sets, choke cavities, and a stock material feeder for feeding a strip of stock material into the die assembly, along with the rotary carousel assembly;
- FIG. 11 is a fragmentary view of a portion of the rotary carousel assembly of FIG. 10 ;
- FIG. 12 is a schematic, exaggerated view of the helical strip that forms the core of FIG. 1 , the core formed via winding the strip around the pole pieces of FIG. 1 ;
- FIG. 13A is a fragmentary view showing the progressive reception of pole pieces into the gaps of the body segments of a strip, the pole pieces and body segments having an interface according to an alternative embodiment
- FIG. 13B is a fragmentary view showing the progressive reception of pole pieces into the gaps of the body segments of a strip, the pole pieces and body segments having an interface according to another alternative embodiment
- FIG. 14 is a view of a known annular laminated article formed as a stack of annular laminations
- FIG. 15 is a fragmentary view of a portion of an annular laminated article manufactured by the present method.
- FIG. 16A is an exploded view of a pole piece and a bobbin having electrical windings
- FIG. 16B is a fragmentary view of a portion of the bobbin and windings of FIG. 16A ;
- FIG. 17 is a fragmentary view of a portion of the rotary carousel, showing a pole piece and bobbin held between a pair of locating blocks of the carousel.
- annular laminated article 20 provides an apparatus and method for production of a relatively large diameter annular component without excessive waste of material.
- annular laminated article 20 includes core 22 and multiple pole pieces 24 , and may be used as an electric motor stator or in other applications, for example.
- the present method may be used to produce other types of annular laminated articles, such as rotors for electric motors.
- Pole piece 24 is shown, which may be manufactured using the die assemblies and methods of the present disclosure.
- Pole piece 24 includes a plurality of stacked and identical individual laminas 26 , which are interlocked with respect to one another in the manner described below.
- Laminas 26 of pole piece 24 include punched features, and in other embodiments the laminas 26 of a given pole piece 24 may vary in overall shape or profile rather than having identical shapes throughout a given pole piece 24 .
- pole pieces 24 may include different types of laminas, made from different materials, which are formed from two different strips of stock material in the manner described in U.S. Pat. Nos. 7,337,531 and 7,676,906, both assigned to the assignee of the present invention, the disclosures of which are expressly incorporated herein by reference.
- Pole piece 24 includes top side 28 defined by an uppermost lamina 26 of pole piece 24 , and bottom side 30 defined by a lowermost lamina 26 of pole piece 24 .
- Pole piece 24 further includes front side 32 , rear side 34 , left side 36 , and right side 38 , each defined collectively by the peripheral edges of individual laminas 26 .
- the profile of the exemplary pole piece 24 , and each individual lamina 26 is generally key-shaped, having proximal or pole piece end portion 40 , body portion 42 , and a distal protruding end portion 44 which interfaces and is secured with respect to core 22 in the manner described below.
- Proximal end portion 40 includes front side 32 , which includes substantially planar or arcuate vertical side 46 , a first pair of substantially shorter and parallel planar vertical walls 48 , and a second pair of angled planar vertical walls 50 .
- Walls 48 extend from wall 46
- walls 50 extend from walls 48 , are angled with respect to one another, and connect to elongate inner portion 42 .
- Body portion 42 has a generally rectangular profile and includes interlock tabs 52 . When the annular component is used as a stator, motor windings (not shown) are wound about body portion 42 .
- a second end of body portion 42 connects to distal protruding end portion 44 , which has a substantially planar vertical wall 54 adjoining a substantially hemispherically-profiled, arcuate opposite vertical wall 56 .
- Vertical wall 54 is formed by the aligned vertical edges of each lamination of pole piece 24
- hemispherically-profiled wall is formed by the aligned hemisphericaly-profiled edges of each lamination of pole piece 24 .
- each of laminas 26 includes a plurality of interlock tabs 52 formed therein.
- Each interlock tab 52 extends slightly outwardly from one side of a lamina to thereby define a corresponding interlock recess 58 in the opposite side of the lamina.
- interlock tabs 52 extend from respective sides of their laminas by a distance which is less than the thickness of the stock material from which the laminas are formed.
- Bottom lamina 26 of pole piece 24 includes a set of apertures 60 punched therein to receive interlock tabs 52 of the next, upper adjacent lamina 26 of pole piece 24 and, other than bottom lamina 26 , interlock tabs 52 of each lamina 26 of pole piece 24 interlock into interlock recesses 58 of an adjacent lower lamina to thereby interlock all of laminas 26 of pole piece 24 with one another.
- interlock tabs 52 , recesses 58 , and apertures 60 are shown herein as rectangular in shape, the shape of the same may vary, as discussed in the foregoing patents.
- first die assembly 62 may be used to manufacture pole pieces from a strip of stock material, such as exemplary lamina or pole piece stacks 24 , shown in FIGS. 1-3 and described above.
- die assembly 62 generally includes lower die assembly 64 and upper die assembly 66 .
- Die assembly 62 is installed within a press (not shown) and, in operation, the press reciprocates upper die assembly 66 upwardly and downwardly with respect to fixed lower die assembly 64 in a known manner.
- stock material feeder 68 is used with die assembly 62 to feed a strip of stock material 70 between lower die assembly 64 and upper die assembly 66 .
- individual laminas 26 are shaped, formed, and blanked from strip 70 , and are also stacked and interlocked within die assembly 62 to form pole pieces 24 .
- Strip 70 of the stock material is typically mounted within feeder 68 in the form of a coil, and feeder 68 is operable to feed strip 70 of stock material from the coil into die assembly 62 along the direction of arrow A shown in FIG. 7 .
- Lower die assembly 64 includes lower die bed 72 and may include a set of guide rails (not shown) for guiding strip 70 of stock material through die assembly 62 .
- the guide rails may define feed pathway 74 ( FIG. 6 ) that extends through die assembly 62 along a corresponding feed direction along which strip 70 of stock material is fed.
- Lower die bed 72 of lower die assembly 64 includes a plurality of carbide die inserts 76 in operative alignment with the various punches of upper die assembly 66 for punching pilot holes and lamina features in strip 70 in the manner described below.
- Lower die assembly 64 additionally includes choke assemblies 78 each including a choke cavity 80 at blanking stations 4 - 6 of die assembly 62 , which are adapted to receive laminas blanked from strip 70 , as described below.
- Upper die assembly 66 includes a punch set corresponding to, and aligned along, feed pathway 74 , which includes individual punches which cooperate with die inserts 76 of lower die assembly 64 to punch lamina features in strip 70 , including blanking punches 82 at blanking Stations 4 - 6 of die assembly 62 for blanking, or separating, individual laminas from strip 70 .
- lower and upper die assemblies 64 and 66 include a plurality of die stations along feed pathway 74 at which pilot holes and lamina features are punched in strip 70 of stock material.
- a pair of pilot hole punches 84 ( FIG. 7 ) of upper die assembly 66 initially punch pilot holes 86 ( FIG. 6 ) on opposite sides of strip 70 at Station 1 , which pilot holes are engaged by pilot pins 88 of upper die assembly 66 at various locations throughout die assembly 62 to align and locate strip 70 at each station while other punches of the punch sets are performing stamping, forming, and/or blanking operations on strip 70 .
- a pair of punches 90 and 92 of upper die assembly 66 punch identical first and second sets 94 and 96 of three punched portions that are internally profiled to shape the distal protruding end portion 44 of a lamina as described above.
- the first set of three punched portions is staggered along the width of strip 70 and face in an opposite direction from an opposing or adjacent second set of three punched portions to allow nesting of the laminas for material conservation.
- a plurality of staking punches 98 stake interlock tabs 52 in strip 70 with interlock tabs 52 formed in each lamina 26 except bottom lamina 26 in pole piece 24 , as described above.
- Staking punches 98 of Station 3 may be selectively actuable, as described in above incorporated U.S. Pat. No. 7,676,906.
- a cam assembly (not shown) regulates the downward movement of punches 98 , allowing punches 98 to function in both a staking manner, in which punches 98 create interlock tabs 52 which are not separated from the laminas, and in an intermittently actuable manner to allow a greater downward movement of punches 98 to form apertures 60 of a bottom lamina 26 .
- blanking punches 82 respectively separate individual laminas from strip 70 while concurrently transferring the same into respective choke cavities 80 and interlocking the blanked lamina with the next, adjacent lower lamina in choke cavities 80 in a process similar to that described in above incorporated U.S. Pat. No. 6,745,458 to Neuenschwander. Blanking punches 82 also shape the remainder of the profile of laminas 26 , as described above.
- Each of Stations 4 - 6 blank a pair of laminas, with the Stations 4 - 6 longitudinally separated along the die and the laminas nested as shown with respect to the strip in order to prevent excessive waste of the strip stock material.
- FIG. 4 illustrates a fragmentary view of a portion of core 22 , showing individual layers 100 A and 100 B of a continuous strip 100 of material that forms core 22 . Ends 101 and 102 of the strip are shown in FIGS. 4 and 5 , respectively, and may be secured to strip 100 by welding, as described below.
- strip 100 of core 22 includes body segments 104 .
- Body segments 104 each include a slightly curved exterior surface 108 ( FIG. 9 ).
- Body segments 104 are connected via hinge portions 106 defined between, and disposed adjacent, exterior surfaces 108 of adjacent body segments 104 .
- Body segments 104 each further include a correspondingly curved interior surface 112 .
- Body segments 104 are separated by gaps 110 which generally include relief portions 111 adjacent hinge portions 106 , and recesses 113 adjacent interior surfaces 112 of adjacent body segments 104 .
- Recesses 113 are shaped complimentary to distal protruding ends 44 of pole pieces 24 , and ends 44 of pole pieces 24 are captured within recesses 113 as described below.
- second die assembly 114 is shown, which is used to manufacture strip 100 of core 22 shown in FIGS. 1 , 4 , 5 , and 9 and described above.
- die assembly 114 generally includes lower die assembly 116 and upper die assembly 118 .
- Die assembly 114 is installed within a press (not shown) and, in operation, the press reciprocates upper die assembly 118 upwardly and downwardly with respect to fixed lower die assembly 116 in a known manner.
- die assembly 114 is “different” from die assembly 62 to the extent that die assembly 114 is configured to produce strip 100 while die assembly 62 is configured to produce pole pieces 24 .
- die assemblies 114 and 62 will also be physically separate from one another and operated by different presses, though it is contemplated that die assemblies 114 and 62 could also be different from one another in the manner described above, i.e., designed to produce different parts, and yet integrated into a single overall die assembly operated by a single press and having separate material stock feeding devices for strips 70 and 100 .
- stock material feeder 120 is used with die assembly 114 to feed a strip of stock material 100 between lower die assembly 116 and upper die assembly 118 .
- Strip 100 of the stock material is typically mounted within feeder 120 in the form of a coil, and feeder 120 is operable to feed strip 100 of stock material from the coil into die assembly 114 along the direction of arrow B shown in FIG. 10 .
- Lower die assembly 116 includes lower die bed 122 and may include a set of guide rails (not shown) for guiding strip 100 of stock material through die assembly 114 .
- the guide rails may define feed pathway 124 ( FIG. 8 ) that extends through die assembly 114 through which strip 100 of stock material is fed along a corresponding feed direction.
- Lower die bed 122 of lower die assembly 116 includes a plurality of carbide die inserts 126 in operative alignment with the various punches of upper die assembly 118 for punching pilot holes and blanks in strip 100 in the manner described below.
- Lower die assembly 116 additionally includes waste cavities 130 at Stations 1 - 4 of die assembly 114 , which are adapted to receive the waste of strip portions blanked from strip 100 , as described below.
- Upper die assembly 118 includes a punch set corresponding to, and aligned along, feed pathway 124 , which includes individual punches which cooperate with die inserts 126 of lower die assembly 116 to punch features in strip 100 .
- lower and upper die assemblies 116 and 118 include a plurality of die stations along feed pathway 124 ( FIG. 8 ) at which pilot holes and lamina features are punched in strip 100 of stock material, and in which features are formed in strip 100 .
- Pilot hole punch 132 ( FIG. 10 ) of upper die assembly 118 initially punches pilot hole 134 in strip 100 at Station 1 , which pilot hole is engaged by pilot pins 136 of upper die assembly 118 at various locations throughout die assembly 114 to align and locate strip 100 at each station while other punches of the punch sets are performing stamping, forming, and/or blanking operations on strip 100 .
- a first elongated punch 138 of upper die assembly 118 punches a first elongated portion 137 ( FIG. 8 ) from one side of strip 100 to define interior surfaces 112 of body segments 104 as well as a set of three equally spaced first relief holes 140 ( FIG. 8 ).
- a set of three punches 142 remove portions 143 ( FIG. 8 ) of strip 100 to form gaps 110 and recesses 113 that are correspondingly shaped to the profile of distal protruding end portion 44 of pole piece 24 , with the removed portions terminating in second relief holes 144 ( FIG. 9 ) disposed proximate first relief holes 140 .
- second elongated punch 146 ( FIG. 10 ) of upper die assembly 118 punches a second elongate portion 139 ( FIG. 8 ) from a side of strip 100 opposite from the side punched by first elongated punch 138 to define exterior surfaces 108 of body segments 104 .
- the second elongated punch 146 also removes material around first relief holes 140 to provide a semi-circular shape for reliefs 140 as may be seen in FIG. 9 and which, together with second relief holes 144 , define hinge portions 106 between body segments 104 .
- die assembly 114 produces a continuous strip 100 with minimal waste of material which, as described in detail below, is wound about a rotary carousel as strip 100 is advanced from die assembly 114 to form core 22 of laminated article 20 in a continuous manner.
- pole pieces 24 and core strip 100 are made of the same material, such as stainless steel or any low or high grade electrical steel.
- pole pieces 24 and core strip 100 may be formed of different materials, depending upon the magnetic properties desired for the annular article.
- pole pieces 24 may be formed of a high grade electrical steel while core strip 100 is made of a low grade electrical steel, or vice-versa, for cost reduction.
- pole pieces 24 of any given annular article may be formed of different materials, or may have differing shapes. In this manner, because pole pieces 24 and core strip 100 are initially formed separately from one another using different dies in the present method, these components may be selectively tailored with respect to one another as to materials and/or shape as desired.
- FIGS. 10 and 11 illustrate rotary carousel 148 , which includes base assembly 154 including rotary shaft 155 and actuator unit 159 .
- Base plate 156 is mounted to shaft 155 , and shaft 155 and carousel 148 are rotatable about axis 157 , as indicated by arrow C in FIG. 10 .
- Axis 157 is also the central longitudinal axis of core 22 .
- Actuator unit 159 FIG.
- Actuator unit 159 may include a motor which operates either to continuously rotate shaft 155 and base plate 156 of carousel 148 in a manner which is timed with the advancement of strip 100 from die assembly 114 , or such a motor may operate in a stepped fashion which is coordinated with the reciprocation of die assembly 114 . In either embodiment, the operation of die assembly 114 , and thus the rate of advancement of strip 100 , is timed to coincide with the rotation of carousel 148 so that strip 100 is fed onto, and wound around, carousel 148 layer by layer.
- FIG. 11 illustrates a fragmentary view of a portion of rotary carousel 148 , showing base plate 156 , which includes a plurality of locating blocks 150 secured to base plate 156 by bolts 158 .
- Locating blocks 150 define spaces therebetween which are dimensioned for receipt of pole pieces 24 .
- Pole pieces 24 are positioned within the spaces between locating blocks by hand, or may be automatically placed by a mechanical placement device (not shown).
- Proximal end portions 40 of pole pieces 24 are positioned towards an interior of carousel 148
- distal protruding end portions 44 of pole pieces 24 are positioned toward an exterior of carousel 148 , and protrude outwardly of locating blocks 150 for receipt of strip 100 as described below.
- strip 100 continues along a path in which it is wound about rotary carousel 148 , and strip 100 typically will have a thickness that is substantially similar to a thickness of each individual lamination of pole pieces 24 . In other embodiments, the thickness of strip 100 may differ from the thickness of the individual laminations of pole pieces 24 .
- carousel 148 is rotated by actuation device 159 ( FIG. 10 ) to wind strip 100 about the exterior of carousel 148 .
- Guide rollers 162 shown in FIG. 8 in the form of spring-tensioned contact roller devices including roller members 163 and springs 165 , for example, may engage the outer periphery 108 of body segments 104 of strip 100 to aid in holding strip 100 in position and preventing strip 100 from initially detaching from distal end portions 44 of pole pieces 24 .
- guide rollers 162 may be used to guide the initial feeding of strip 100 onto pole pieces 24 when strip 100 is first advanced from die assembly 114 onto carousel 148 .
- FIG. 9 the winding of strip 100 around pole pieces 24 of carousel 148 is shown, with the details of carousel 148 omitted for clarity to more clearly illustrate the progressive capturing of distal end portions 44 of pole pieces 24 within gaps 110 between body segments 104 of strip 100 .
- body segments 104 close about hinge portions 106 and via gaps 110 to capture the correspondingly shaped distal end portions 44 of pole pieces 24 to secure pole pieces 24 to core 22 as core 22 is formed by progressively winding strip of 100 in a layer-by-layer manner around carousel 148 and pole pieces 24 .
- relief holes 144 and 140 facilitate bending deformation of hinge portions 106 to allow recesses 113 to collapse about, and capture, distal end portions 44 of pole pieces 24 between adjacent body segments 104 of strip 100 .
- a linear lead-in edge 54 of a lamina of end portion 44 of pole piece 24 engages a corresponding linear edge of a lamina of body segment 104 , followed by recess 113 of a lamina of body segment 104 closing onto, and engaging, the hemispherical edge 56 of a lamina of pole piece 24 .
- the convex profile of distal end portions 44 of pole pieces 24 conforms to the concave profile of recesses 113 and, in the embodiment shown in FIG. 9 , allows a limited extent of relative rotational movement between distal end portions 44 of pole pieces 24 and body segments 104 as recesses 113 of body segments 104 progressively close onto distal end portions 44 .
- distal end portions 44 of pole pieces 24 are captured between body segments 104 of strip 100 , with further rotation of carousel 148 and progression of this process more and more laminas 26 of pole pieces 24 are secured with respect to the layers of strip 100 as core 22 is formed.
- the capture of distal end portions 44 of pole pieces 24 between body segments 104 of strip 100 allows carousel 148 to exert a pulling force on strip 100 as strip 100 is produced by die assembly 114 .
- the timing of operation of die assembly 114 and the formation of strip 100 by die assembly 114 is timed to correspond substantially to the take-up of strip 100 onto carousel 148 by the rotation of carousel 148
- carousel 148 may be operated at a slightly increased rate to exert a pulling tension on strip 100 .
- FIG. 10 shows a schematic, exaggerated view of the continuous helical strip 100 that forms core 22 as strip 100 winds about pole pieces 24 and carousel 148 , about axis 157 , until a number of layers of strip 100 are produced that is substantially equal to the number of laminations of each pole piece 24 .
- interlock tabs 52 may be formed in body segments 104 of layers of strip 100 by second die assembly 114 . Such interlock tabs 52 may be separately interlocked during the winding of strip 100 , for example, via staking punches that punch interlock tabs 52 into body segments 104 at periodic intervals in which the strip winding stops to allow for the staking punches to operate.
- interlock tabs 52 of body segments 104 are all interlocked by compression of core 22 via a press device (not shown), after a desired number of layers of strip 100 have been built up around pole pieces 24 .
- the ends of strip 100 are welded onto respective underlying or overlying layers of strip 100 to secure the ends of core 22 .
- the ends 101 and 102 of strip 100 may be secured to core by welding ends 101 and 102 to core 22 at respective welding locations W 1 ( FIG. 4 ) and W 2 ( FIG. 5 ).
- the individual layers of strip 100 may be welded to one another along longitudinal welding points W 3 ( FIG. 4 ) defined along hinge portions 106 between adjacent body segments 104 .
- the completed core 22 may be removed from carousel 148 and subjected to desired finishing operations to form a stator, for example.
- actuating device 159 indexes base plate 156 of carousel upwardly along the direction of arrow E of FIG. 10 to its initial position to allow the above-described process to be repeated to form another core 22 .
- Distal end portions 44 of pole pieces 24 in the embodiment described above have a profile defined by relatively straight wall 54 together with hemispherical wall 56 . As described above, this shape, together with the correspondingly semicircular shape of recesses 113 provided within gaps 110 between adjacent body segments 104 of strip 100 , allows distal end portions 44 of pole pieces 24 to be received and captured within recesses 113 and gaps 110 upon bending deformation of strip 104 about hinge portions 106 between adjacent body segments 104 . However, the shape of distal end portions 44 , as well as the corresponding profiles of gaps 110 , may vary.
- FIGS. 13A and 13B alternative shapes or profiles for the distal end portions 44 of pole pieces 24 and corresponding features in strip 100 are shown.
- a half-dovetail interface is shown between pole piece 24 and strip 100 , in which distal end portion 44 of pole piece 24 includes a half-dovetail projection 170 having a first, distal wall 172 normal to the longitudinal axis of pole piece 24 , an first angled second dovetail or locking wall 174 , and a third, angled lead-in wall 176 .
- Strip 100 includes a corresponding dovetail recess 178 defined by first walls 180 , a second angled dovetail or locking wall 182 in a first body segment 104 , and a third, angled lead-in wall 184 in the adjacent body segment 104 of strip 100 .
- body segments 104 of strip 100 close about hinge portions 106 with the third, lead-in walls 176 and 184 initially engaging one another, followed by engagement of first walls 172 and 180 and concluding with second walls 182 of body segments 104 closing about and engaging second walls 174 of distal end portions 44 of pole pieces 24 to capture distal end portions 44 of pole pieces 24 and secure pole pieces 24 to core 22 .
- the half-dovetail engagement between angled second walls 174 and 182 of pole pieces 44 and body segments 104 respectively, firmly locks pole pieces 44 in place between body segments 104 of strip 100 .
- FIG. 13B an alternative half-dovetail interface between pole piece 24 and strip 100 is shown, in which body segments 104 of strip 100 include additional recesses 186 which close about shoulder portions 188 of distal end portions 44 of pole pieces 24 .
- a full dovetail interface may be used between pole piece 24 and strip 100 to provide a still more rigid locking interface between the pole pieces 24 and core 22 .
- Other types of interlocking interfaces between the pole pieces 24 and core 22 may be used.
- electrical windings may be wound onto pole pieces 24 prior to loading of pole pieces 24 into carousel 148 .
- electrical windings 190 may be would about bobbins 192 , which may be made of an insulating material such as a plastic and shaped to fit over pole pieces 24 .
- bobbins 192 may include recesses 194 to located the initial winding layer of windings 190 and thereby aid in the uniform winding of windings 190 about bobbins 192 . Then, as shown in FIG.
- pole pieces 24 with bobbins 192 may be loaded on to carousel 148 between pairs of locating blocks 150 , followed by winding strip 100 around pole pieces 24 to form core 22 of article 20 , as described above.
- an insulation material (not shown) may be over-molded directly onto pole pieces 24 followed by winding windings 190 directly onto pole pieces 24 over the insulating layer.
- pole pieces are “pre-wound” prior to formation of article 20 , which may be advantageous in the event the particular geometry of core 22 and pole pieces 24 would make winding of pole pieces 24 difficult after formation of article 20 .
- carousel 148 may be configured such that multiple horizontal levels of sets of pole pieces 24 may be held by carousel 148 , perhaps with spacer members (not shown) disposed between the individual pole piece layers. This configuration would allow several layers of pole pieces 24 to be loaded onto carousel 148 during a common loading operation, with several cores 22 formed respectively about the pole piece layers. Between each layer, strip 100 would be cut, carousel 148 would be vertically indexed, and strip 100 would be sequenced to and wound about a next level of pole pieces 24 to form a new article 20 . In this manner, a number of annular laminated parts 20 may be formed via a continuous operation without having to remove each part 20 and re-load carousel 148 with pole pieces 24 after the formation of each annular laminated part 20 .
- die assembly 114 may operate using a strip accumulator device (not shown), such that strip 100 is not wound about carousel 148 directly upon exiting die assembly 114 .
- strip 100 is accumulated on the strip accumulator device, such as being wound around a rotary accumulator or being overlapped by a ribbon accumulator, before being would about carousel 148 .
- the use of a strip accumulator device allows die assembly 114 to operate continuously even when carousel 148 is not itself operational to receive strip 100 , such as when conducting welding operations on a completed core 22 , during removal of a completed article 20 from carousel 148 , and/or loading of carousel 148 with pole pieces 24 .
- annular laminated articles 20 by the present method involves the ability to selectively tailor and align the grain direction of the metal within a given laminated article 20 .
- the grain of each annular lamina 202 will be representative of the grain of the strip of material from which the laminas 202 are stamped.
- strips of metal stock material will have a grain direction extending parallel to, and along, the strip itself.
- the grain direction in any given lamina 202 will be unidirectional throughout the lamina 202 , as illustrated by grain direction arrows GD 1 .
- laminated articles 20 manufactured via the present method may be manufactured using two or more different die assemblies, and include a core 22 and pole pieces 24 which may be formed from different strips of stock material.
- the strips of stock material from which core 22 and pole pieces 24 are formed each have a grain direction extending parallel to, and along, the strips of stock material
- the core 22 and pole pieces 24 of the resulting article 20 will have differing grain directions.
- the pole pieces 24 will have grain directions extending along arrows GD 2 along the longitudinal axes of pole pieces 24 and which, in the resulting article 20 , will each extend radially similar to the spokes of a wheel.
- Body segments 104 of core 22 will have grain directions extending along arrows GD 3 generally parallel to the interior and exterior edges of body segments 104 such that core 22 will have a grain direction resulting from its combined body segments 104 that extends around the annular periphery of core 22 and approximates a circle with respect to a given layer of core 22 , or a helix with respect to the multiple layers of core 22 .
- use of strips of stock material having differing grain directions and/or stamping pole pieces 24 in selected differing orientations with respect to the grain direction of the strip of stock material from which pole pieces 24 are stamped allows the grain directions within any given article to be selectively tailored to in turn tailor and/or enhance the magnetic properties of the article.
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Abstract
Description
- This application claims priority under Title 35, U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/375,159, filed Aug. 19, 2010, entitled CONTINUOUSLY FORMED ANNULAR LAMINATED ARTICLE AND METHOD FOR ITS MANUFACTURE, the entire disclosure of which is hereby expressly incorporated by reference herein.
- 1. Field of Invention
- The present invention relates to progressive die assemblies that are used to manufacture relatively large diameter annular components, such as stator cores for electric motors.
- 2. Description of Related Art
- It is well known to manufacture annular laminated parts, such as stator cores, in a manner in which individual annular laminations are stamped from a strip of steel stock material by a progressive die apparatus and are stacked and interlocked to form the part.
- However, because each annular lamination is formed as a single piece, the width of the steel strip needs to be at least as large as the outer diameter of the lamination. Thus, disadvantageously, a relatively large amount of the steel material is wasted when manufacturing annular laminated parts via known processes, for example, the material between adjacent laminations and within the interior of each lamination.
- In the past, material waste was minimized by manufacturing a rotor core from the central portion of the stator laminations and/or by stamping the stator laminations in rows that were staggered with respect to one another. However, with the use of relatively new electrically commutated motors (ECM), which do not include a rotor core, material waste is much more of a concern as, for example, a central portion of large diameter stator lamination which is stamped as an annular part may remain unused.
- A need exists for a high speed die assembly or assemblies capable of creating relatively large diameter annular laminated parts without excessive waste of the stock material from which the annular laminated parts are formed.
- The present disclosure provides an apparatus and method for the production of relatively large diameter annular components, such as stator cores for electric motors, without excessive waste of material. In one embodiment, a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations. The pole pieces, having protruding end portions, are loaded into a rotary carousel. A second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces. As the continuous strip is formed, it is wound about the rotary carousel with progressive pivoting of the body segments about the hinge portions to capture the protruding ends of the pole pieces within the recesses, with continued winding of the strip in a helical fashion around the rotary carousel continuing until a desired height is reached that is substantially equivalent to the height of the pole pieces. The strip is then cut, and the resulting annular part is welded at one or more locations to secure the components together.
- In one form thereof, the present disclosure provides a method of forming an annular article, including the steps of: forming a plurality of pole pieces by forming, stacking, and interlocking a plurality of individual laminations in a first die assembly; loading the plurality of pole pieces onto a rotary carousel; forming a continuous strip in a second die assembly, the continuous strip including a plurality of body segments separated by gaps, the body segments connected via hinge portions; and rotating the carousel with concurrent winding of the strip around the carousel to progressively capture distal ends of the pole pieces within the gaps by pivoting the body segments about the hinge portions.
- In another form thereof, the present disclosure provides an annular laminated article, including an annular core portion including a plurality of body segments connected by hinge portions; and a plurality of pole pieces separate from the core portion, each pole piece including an end portion captured between an adjacent pair of body segments.
- The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following descriptions of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
-
FIG. 1 is a perspective view of an annular laminated article according to an exemplary embodiment, the article including a core and multiple pole pieces; -
FIG. 2 is a perspective view of an exemplary pole piece of the annular laminated article ofFIG. 1 ; -
FIG. 3 is a cross-sectional view taken along line 3-3 ofFIG. 1 showing the interlocking between individual laminations of the pole piece; -
FIG. 4 is a fragmentary view of a portion of the core ofFIG. 1 ; -
FIG. 5 is a fragmentary view of another portion of the core ofFIG. 1 ; -
FIG. 6 is a strip layout of a first die assembly according to the present disclosure; -
FIG. 7 is an elevational, partially sectioned view of the first die assembly, showing the lower die assembly, the upper die assembly, punch sets, choke cavities, and a stock material feeder for feeding a strip of stock material into the die assembly; -
FIG. 8 is a strip layout of a second die assembly according to the present disclosure, also showing a rotary carousel configuration including the pole pieces ofFIG. 1 , about which the strip formed by the second die assembly is wound upon rotation of the rotary carousel assembly; -
FIG. 9 is a fragmentary view showing the progressive reception of pole pieces into the gaps of the body segments of the strip ofFIG. 8 ; -
FIG. 10 is an elevational, partially sectioned view of the second die assembly, showing the lower die assembly, the upper die assembly, punch sets, choke cavities, and a stock material feeder for feeding a strip of stock material into the die assembly, along with the rotary carousel assembly; -
FIG. 11 is a fragmentary view of a portion of the rotary carousel assembly ofFIG. 10 ; -
FIG. 12 is a schematic, exaggerated view of the helical strip that forms the core ofFIG. 1 , the core formed via winding the strip around the pole pieces ofFIG. 1 ; -
FIG. 13A is a fragmentary view showing the progressive reception of pole pieces into the gaps of the body segments of a strip, the pole pieces and body segments having an interface according to an alternative embodiment; -
FIG. 13B is a fragmentary view showing the progressive reception of pole pieces into the gaps of the body segments of a strip, the pole pieces and body segments having an interface according to another alternative embodiment; -
FIG. 14 is a view of a known annular laminated article formed as a stack of annular laminations; -
FIG. 15 is a fragmentary view of a portion of an annular laminated article manufactured by the present method; -
FIG. 16A is an exploded view of a pole piece and a bobbin having electrical windings; -
FIG. 16B is a fragmentary view of a portion of the bobbin and windings ofFIG. 16A ; and -
FIG. 17 is a fragmentary view of a portion of the rotary carousel, showing a pole piece and bobbin held between a pair of locating blocks of the carousel. - Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.
- The present invention provides an apparatus and method for production of a relatively large diameter annular component without excessive waste of material. Referring to
FIG. 1 , such an annular component is shown as annular laminatedarticle 20 according to an exemplary embodiment. Annular laminatedarticle 20 includescore 22 andmultiple pole pieces 24, and may be used as an electric motor stator or in other applications, for example. The present method may be used to produce other types of annular laminated articles, such as rotors for electric motors. - Referring to
FIGS. 2 and 3 , anexemplary pole piece 24 is shown, which may be manufactured using the die assemblies and methods of the present disclosure.Pole piece 24 includes a plurality of stacked and identicalindividual laminas 26, which are interlocked with respect to one another in the manner described below. Laminas 26 ofpole piece 24 include punched features, and in other embodiments thelaminas 26 of a givenpole piece 24 may vary in overall shape or profile rather than having identical shapes throughout a givenpole piece 24. - Further details regarding lamina stacks including individual lamina layers that may have various outside perimeter shapes and that may have two or more discrete lamina portions, and the manner of manufacturing the same, are described in the above-incorporated U.S. Pat. Nos. 6,163,949 and 7,600,312 to Neuenschwander. Additionally,
pole pieces 24 may include different types of laminas, made from different materials, which are formed from two different strips of stock material in the manner described in U.S. Pat. Nos. 7,337,531 and 7,676,906, both assigned to the assignee of the present invention, the disclosures of which are expressly incorporated herein by reference. -
Pole piece 24 includestop side 28 defined by anuppermost lamina 26 ofpole piece 24, andbottom side 30 defined by alowermost lamina 26 ofpole piece 24.Pole piece 24 further includesfront side 32,rear side 34,left side 36, andright side 38, each defined collectively by the peripheral edges ofindividual laminas 26. The profile of theexemplary pole piece 24, and eachindividual lamina 26, is generally key-shaped, having proximal or polepiece end portion 40,body portion 42, and a distalprotruding end portion 44 which interfaces and is secured with respect tocore 22 in the manner described below. -
Proximal end portion 40 includesfront side 32, which includes substantially planar or arcuatevertical side 46, a first pair of substantially shorter and parallel planarvertical walls 48, and a second pair of angled planarvertical walls 50.Walls 48 extend fromwall 46, andwalls 50 extend fromwalls 48, are angled with respect to one another, and connect to elongateinner portion 42. -
Body portion 42 has a generally rectangular profile and includesinterlock tabs 52. When the annular component is used as a stator, motor windings (not shown) are wound aboutbody portion 42. A second end ofbody portion 42 connects to distalprotruding end portion 44, which has a substantially planarvertical wall 54 adjoining a substantially hemispherically-profiled, arcuate oppositevertical wall 56.Vertical wall 54 is formed by the aligned vertical edges of each lamination ofpole piece 24, and hemispherically-profiled wall is formed by the aligned hemisphericaly-profiled edges of each lamination ofpole piece 24. - Additionally, as shown in
FIGS. 2 and 3 , and described further below, each oflaminas 26, except forbottom lamina 26 ofpole piece 24, includes a plurality ofinterlock tabs 52 formed therein. Eachinterlock tab 52 extends slightly outwardly from one side of a lamina to thereby define acorresponding interlock recess 58 in the opposite side of the lamina. Typically,interlock tabs 52 extend from respective sides of their laminas by a distance which is less than the thickness of the stock material from which the laminas are formed.Bottom lamina 26 ofpole piece 24 includes a set ofapertures 60 punched therein to receiveinterlock tabs 52 of the next, upperadjacent lamina 26 ofpole piece 24 and, other thanbottom lamina 26,interlock tabs 52 of eachlamina 26 ofpole piece 24 interlock into interlock recesses 58 of an adjacent lower lamina to thereby interlock all oflaminas 26 ofpole piece 24 with one another. - The foregoing interlock arrangement for interlocking laminas in a stack is described in detail in U.S. Pat. Nos. 4,619,028, 5,241,138, 5,349,741, 6,163,949, 6,745,458, and 7,600,312 to Neuenschwander, each assigned to the assignee of the present invention, the disclosure of which are expressly incorporated herein by reference. Although
interlock tabs 52, recesses 58, andapertures 60 are shown herein as rectangular in shape, the shape of the same may vary, as discussed in the foregoing patents. - Referring to
FIGS. 6 and 7 ,first die assembly 62 according to the present invention is shown. First dieassembly 62 may be used to manufacture pole pieces from a strip of stock material, such as exemplary lamina or pole piece stacks 24, shown inFIGS. 1-3 and described above. Referring toFIG. 7 , dieassembly 62 generally includeslower die assembly 64 andupper die assembly 66.Die assembly 62 is installed within a press (not shown) and, in operation, the press reciprocatesupper die assembly 66 upwardly and downwardly with respect to fixed lower dieassembly 64 in a known manner. - Referring to
FIG. 7 ,stock material feeder 68 is used withdie assembly 62 to feed a strip ofstock material 70 betweenlower die assembly 64 andupper die assembly 66. As described below,individual laminas 26 are shaped, formed, and blanked fromstrip 70, and are also stacked and interlocked withindie assembly 62 to formpole pieces 24.Strip 70 of the stock material is typically mounted withinfeeder 68 in the form of a coil, andfeeder 68 is operable to feedstrip 70 of stock material from the coil intodie assembly 62 along the direction of arrow A shown inFIG. 7 .Lower die assembly 64 includeslower die bed 72 and may include a set of guide rails (not shown) for guidingstrip 70 of stock material throughdie assembly 62. The guide rails may define feed pathway 74 (FIG. 6 ) that extends throughdie assembly 62 along a corresponding feed direction along which strip 70 of stock material is fed. - Lower die
bed 72 oflower die assembly 64 includes a plurality of carbide die inserts 76 in operative alignment with the various punches ofupper die assembly 66 for punching pilot holes and lamina features instrip 70 in the manner described below.Lower die assembly 64 additionally includeschoke assemblies 78 each including achoke cavity 80 at blanking stations 4-6 ofdie assembly 62, which are adapted to receive laminas blanked fromstrip 70, as described below.Upper die assembly 66 includes a punch set corresponding to, and aligned along,feed pathway 74, which includes individual punches which cooperate with die inserts 76 oflower die assembly 64 to punch lamina features instrip 70, including blanking punches 82 at blanking Stations 4-6 ofdie assembly 62 for blanking, or separating, individual laminas fromstrip 70. - Referring to
FIGS. 6 and 7 , lower andupper die assemblies feed pathway 74 at which pilot holes and lamina features are punched instrip 70 of stock material. A pair of pilot hole punches 84 (FIG. 7 ) ofupper die assembly 66 initially punch pilot holes 86 (FIG. 6 ) on opposite sides ofstrip 70 atStation 1, which pilot holes are engaged bypilot pins 88 ofupper die assembly 66 at various locations throughoutdie assembly 62 to align and locatestrip 70 at each station while other punches of the punch sets are performing stamping, forming, and/or blanking operations onstrip 70. AtStation 2, a pair ofpunches upper die assembly 66 punch identical first andsecond sets protruding end portion 44 of a lamina as described above. The first set of three punched portions is staggered along the width ofstrip 70 and face in an opposite direction from an opposing or adjacent second set of three punched portions to allow nesting of the laminas for material conservation. - At
Station 3, a plurality of stakingpunches 98stake interlock tabs 52 instrip 70 withinterlock tabs 52 formed in eachlamina 26 exceptbottom lamina 26 inpole piece 24, as described above. Staking punches 98 ofStation 3 may be selectively actuable, as described in above incorporated U.S. Pat. No. 7,676,906. For example, a cam assembly (not shown) regulates the downward movement ofpunches 98, allowingpunches 98 to function in both a staking manner, in which punches 98 createinterlock tabs 52 which are not separated from the laminas, and in an intermittently actuable manner to allow a greater downward movement ofpunches 98 to formapertures 60 of abottom lamina 26. - At Stations 4-6, blanking
punches 82 respectively separate individual laminas fromstrip 70 while concurrently transferring the same intorespective choke cavities 80 and interlocking the blanked lamina with the next, adjacent lower lamina inchoke cavities 80 in a process similar to that described in above incorporated U.S. Pat. No. 6,745,458 to Neuenschwander. Blanking punches 82 also shape the remainder of the profile oflaminas 26, as described above. - Each of Stations 4-6 blank a pair of laminas, with the Stations 4-6 longitudinally separated along the die and the laminas nested as shown with respect to the strip in order to prevent excessive waste of the strip stock material.
- Referring to
FIGS. 1 , 4, and 5,core 22 is assembled about thepole pieces 24 to form annularlaminated article 20 in the manner described below.FIG. 4 illustrates a fragmentary view of a portion ofcore 22, showingindividual layers 100A and 100B of acontinuous strip 100 of material that formscore 22.Ends FIGS. 4 and 5 , respectively, and may be secured to strip 100 by welding, as described below. - Referring to
FIGS. 4 , 5, and 9,strip 100 ofcore 22 includesbody segments 104.Body segments 104 each include a slightly curved exterior surface 108 (FIG. 9 ).Body segments 104 are connected viahinge portions 106 defined between, and disposed adjacent,exterior surfaces 108 ofadjacent body segments 104.Body segments 104 each further include a correspondingly curvedinterior surface 112.Body segments 104 are separated bygaps 110 which generally include relief portions 111adjacent hinge portions 106, and recesses 113 adjacentinterior surfaces 112 ofadjacent body segments 104.Recesses 113 are shaped complimentary to distal protruding ends 44 ofpole pieces 24, and ends 44 ofpole pieces 24 are captured withinrecesses 113 as described below. - Referring to
FIGS. 8 and 10 ,second die assembly 114 is shown, which is used to manufacturestrip 100 ofcore 22 shown inFIGS. 1 , 4, 5, and 9 and described above. Referring toFIG. 10 , dieassembly 114 generally includeslower die assembly 116 andupper die assembly 118. Dieassembly 114 is installed within a press (not shown) and, in operation, the press reciprocatesupper die assembly 118 upwardly and downwardly with respect to fixedlower die assembly 116 in a known manner. As disclosed herein, dieassembly 114 is “different” fromdie assembly 62 to the extent that dieassembly 114 is configured to producestrip 100 while dieassembly 62 is configured to producepole pieces 24. Typically, dieassemblies assemblies strips - Referring to
FIG. 10 ,stock material feeder 120 is used withdie assembly 114 to feed a strip ofstock material 100 betweenlower die assembly 116 andupper die assembly 118.Strip 100 of the stock material is typically mounted withinfeeder 120 in the form of a coil, andfeeder 120 is operable to feedstrip 100 of stock material from the coil intodie assembly 114 along the direction of arrow B shown inFIG. 10 .Lower die assembly 116 includeslower die bed 122 and may include a set of guide rails (not shown) for guidingstrip 100 of stock material throughdie assembly 114. The guide rails may define feed pathway 124 (FIG. 8 ) that extends throughdie assembly 114 through whichstrip 100 of stock material is fed along a corresponding feed direction. -
Lower die bed 122 oflower die assembly 116 includes a plurality of carbide dieinserts 126 in operative alignment with the various punches ofupper die assembly 118 for punching pilot holes and blanks instrip 100 in the manner described below.Lower die assembly 116 additionally includeswaste cavities 130 at Stations 1-4 ofdie assembly 114, which are adapted to receive the waste of strip portions blanked fromstrip 100, as described below.Upper die assembly 118 includes a punch set corresponding to, and aligned along,feed pathway 124, which includes individual punches which cooperate withdie inserts 126 oflower die assembly 116 to punch features instrip 100. - Referring to
FIGS. 8 and 10 , lower andupper die assemblies 116 and 118 (FIG. 10 ) include a plurality of die stations along feed pathway 124 (FIG. 8 ) at which pilot holes and lamina features are punched instrip 100 of stock material, and in which features are formed instrip 100. Pilot hole punch 132 (FIG. 10 ) ofupper die assembly 118 initially punchespilot hole 134 instrip 100 atStation 1, which pilot hole is engaged bypilot pins 136 ofupper die assembly 118 at various locations throughoutdie assembly 114 to align and locatestrip 100 at each station while other punches of the punch sets are performing stamping, forming, and/or blanking operations onstrip 100. - At
Station 2, a firstelongated punch 138 of upper die assembly 118 (FIG. 10 ) punches a first elongated portion 137 (FIG. 8 ) from one side ofstrip 100 to defineinterior surfaces 112 ofbody segments 104 as well as a set of three equally spaced first relief holes 140 (FIG. 8 ). AtStation 3, a set of three punches 142 (FIG. 10 ) remove portions 143 (FIG. 8 ) ofstrip 100 to formgaps 110 and recesses 113 that are correspondingly shaped to the profile of distalprotruding end portion 44 ofpole piece 24, with the removed portions terminating in second relief holes 144 (FIG. 9 ) disposed proximate first relief holes 140. AtStation 4, second elongated punch 146 (FIG. 10 ) ofupper die assembly 118 punches a second elongate portion 139 (FIG. 8 ) from a side ofstrip 100 opposite from the side punched by firstelongated punch 138 to defineexterior surfaces 108 ofbody segments 104. The secondelongated punch 146 also removes material aroundfirst relief holes 140 to provide a semi-circular shape forreliefs 140 as may be seen inFIG. 9 and which, together with second relief holes 144, definehinge portions 106 betweenbody segments 104. - Advantageously, by forming a core strip separately from the pole pieces for later combination with the pre-formed pole pieces, stock material used to form the large diameter annular component is greatly conserved to prevent excessive waste of the material. Also, die
assembly 114 produces acontinuous strip 100 with minimal waste of material which, as described in detail below, is wound about a rotary carousel asstrip 100 is advanced fromdie assembly 114 to formcore 22 oflaminated article 20 in a continuous manner. - In one embodiment,
pole pieces 24 andcore strip 100 are made of the same material, such as stainless steel or any low or high grade electrical steel. In other embodiments,pole pieces 24 andcore strip 100 may be formed of different materials, depending upon the magnetic properties desired for the annular article. For example,pole pieces 24 may be formed of a high grade electrical steel whilecore strip 100 is made of a low grade electrical steel, or vice-versa, for cost reduction. In other embodiments,pole pieces 24 of any given annular article may be formed of different materials, or may have differing shapes. In this manner, becausepole pieces 24 andcore strip 100 are initially formed separately from one another using different dies in the present method, these components may be selectively tailored with respect to one another as to materials and/or shape as desired. -
FIGS. 10 and 11 illustraterotary carousel 148, which includesbase assembly 154 includingrotary shaft 155 andactuator unit 159.Base plate 156 is mounted toshaft 155, andshaft 155 andcarousel 148 are rotatable aboutaxis 157, as indicated by arrow C inFIG. 10 .Axis 157, as shown inFIGS. 1 , 8, 10, and 12, is also the central longitudinal axis ofcore 22. Actuator unit 159 (FIG. 10 ), which may include one or more electric motors or other drive devices, rotatesshaft 155 andcarousel 148 aboutaxis 157, and alsoindexes base plate 156 upwardly and/or downwardly along the direction indicated by arrow D ofFIG. 10 tolower base plate 156 asstrip 100 is fed ontorotary carousel 148 layer by layer, as described below.Actuator unit 159 may include a motor which operates either to continuously rotateshaft 155 andbase plate 156 ofcarousel 148 in a manner which is timed with the advancement ofstrip 100 fromdie assembly 114, or such a motor may operate in a stepped fashion which is coordinated with the reciprocation ofdie assembly 114. In either embodiment, the operation ofdie assembly 114, and thus the rate of advancement ofstrip 100, is timed to coincide with the rotation ofcarousel 148 so thatstrip 100 is fed onto, and wound around,carousel 148 layer by layer. -
FIG. 11 illustrates a fragmentary view of a portion ofrotary carousel 148, showingbase plate 156, which includes a plurality of locatingblocks 150 secured tobase plate 156 bybolts 158. Locatingblocks 150 define spaces therebetween which are dimensioned for receipt ofpole pieces 24.Pole pieces 24 are positioned within the spaces between locating blocks by hand, or may be automatically placed by a mechanical placement device (not shown).Proximal end portions 40 ofpole pieces 24 are positioned towards an interior ofcarousel 148, and distalprotruding end portions 44 ofpole pieces 24 are positioned toward an exterior ofcarousel 148, and protrude outwardly of locatingblocks 150 for receipt ofstrip 100 as described below. - After
strip 100 is formed by the process described above,strip 100 continues along a path in which it is wound aboutrotary carousel 148, and strip 100 typically will have a thickness that is substantially similar to a thickness of each individual lamination ofpole pieces 24. In other embodiments, the thickness ofstrip 100 may differ from the thickness of the individual laminations ofpole pieces 24. - Referring to
FIGS. 8 and 9 , concurrent with the operation ofsecond die assembly 114 and advancement ofstrip 100 therefrom,carousel 148 is rotated by actuation device 159 (FIG. 10 ) towind strip 100 about the exterior ofcarousel 148.Guide rollers 162, shown inFIG. 8 in the form of spring-tensioned contact roller devices includingroller members 163 and springs 165, for example, may engage theouter periphery 108 ofbody segments 104 ofstrip 100 to aid in holdingstrip 100 in position and preventingstrip 100 from initially detaching fromdistal end portions 44 ofpole pieces 24. In particular, guiderollers 162 may be used to guide the initial feeding ofstrip 100 ontopole pieces 24 whenstrip 100 is first advanced fromdie assembly 114 ontocarousel 148. - Referring to
FIG. 9 , the winding ofstrip 100 aroundpole pieces 24 ofcarousel 148 is shown, with the details ofcarousel 148 omitted for clarity to more clearly illustrate the progressive capturing ofdistal end portions 44 ofpole pieces 24 withingaps 110 betweenbody segments 104 ofstrip 100. Asstrip 100 is wound aboutcarousel 148,body segments 104 close abouthinge portions 106 and viagaps 110 to capture the correspondingly shapeddistal end portions 44 ofpole pieces 24 to securepole pieces 24 tocore 22 ascore 22 is formed by progressively winding strip of 100 in a layer-by-layer manner aroundcarousel 148 andpole pieces 24. In particular,relief holes adjacent hinge portions 106, facilitate bending deformation ofhinge portions 106 to allowrecesses 113 to collapse about, and capture,distal end portions 44 ofpole pieces 24 betweenadjacent body segments 104 ofstrip 100. Initially, for a givenpole piece 24, a linear lead-inedge 54 of a lamina ofend portion 44 ofpole piece 24 engages a corresponding linear edge of a lamina ofbody segment 104, followed byrecess 113 of a lamina ofbody segment 104 closing onto, and engaging, thehemispherical edge 56 of a lamina ofpole piece 24. Thus, the convex profile ofdistal end portions 44 ofpole pieces 24 conforms to the concave profile ofrecesses 113 and, in the embodiment shown inFIG. 9 , allows a limited extent of relative rotational movement betweendistal end portions 44 ofpole pieces 24 andbody segments 104 asrecesses 113 ofbody segments 104 progressively close ontodistal end portions 44. Asdistal end portions 44 ofpole pieces 24 are captured betweenbody segments 104 ofstrip 100, with further rotation ofcarousel 148 and progression of this process more and more laminas 26 ofpole pieces 24 are secured with respect to the layers ofstrip 100 ascore 22 is formed. - Advantageously, the capture of
distal end portions 44 ofpole pieces 24 betweenbody segments 104 ofstrip 100 allowscarousel 148 to exert a pulling force onstrip 100 asstrip 100 is produced bydie assembly 114. Thus, although the timing of operation ofdie assembly 114 and the formation ofstrip 100 bydie assembly 114 is timed to correspond substantially to the take-up ofstrip 100 ontocarousel 148 by the rotation ofcarousel 148, in oneembodiment carousel 148 may be operated at a slightly increased rate to exert a pulling tension onstrip 100. - After completion of each rotation of
carousel 148 corresponding to formation of a layer ofcore 22, actuation device 159 (FIG. 10 ) indexes downwardly a distance equal to the thickness ofstrip 100. This allows thestrip 100 to be advanced fromdie assembly 114 as shown inFIG. 10 at a substantially constant horizontal level.FIG. 12 shows a schematic, exaggerated view of the continuoushelical strip 100 that formscore 22 asstrip 100 winds aboutpole pieces 24 andcarousel 148, aboutaxis 157, until a number of layers ofstrip 100 are produced that is substantially equal to the number of laminations of eachpole piece 24. - Referring to
FIGS. 1 , 4, and 5, after a suitable number of layers ofstrip 100 have been wound about carousel to formcore 22,strip 100 is cut. Optionally, as shown inFIGS. 4 and 5 , interlocktabs 52 may be formed inbody segments 104 of layers ofstrip 100 bysecond die assembly 114.Such interlock tabs 52 may be separately interlocked during the winding ofstrip 100, for example, via staking punches that punchinterlock tabs 52 intobody segments 104 at periodic intervals in which the strip winding stops to allow for the staking punches to operate. For instance, the rotation ofcarousel 148 may be paused at the completion of each rotation of carousel to allow the staking to occur after each single layer ofstrip 100 is wound aboutcarousel 148. In an alternative embodiment,interlock tabs 52 ofbody segments 104 are all interlocked by compression ofcore 22 via a press device (not shown), after a desired number of layers ofstrip 100 have been built up aroundpole pieces 24. - After
strip 100 is cut, the ends ofstrip 100 are welded onto respective underlying or overlying layers ofstrip 100 to secure the ends ofcore 22. In particular, referring toFIGS. 4 and 5 , theends strip 100 may be secured to core by welding ends 101 and 102 tocore 22 at respective welding locations W1 (FIG. 4 ) and W2 (FIG. 5 ). Similarly, the individual layers ofstrip 100 may be welded to one another along longitudinal welding points W3 (FIG. 4 ) defined alonghinge portions 106 betweenadjacent body segments 104. Then, the completedcore 22 may be removed fromcarousel 148 and subjected to desired finishing operations to form a stator, for example. Aftercore 22 is removed,actuating device 159indexes base plate 156 of carousel upwardly along the direction of arrow E ofFIG. 10 to its initial position to allow the above-described process to be repeated to form anothercore 22. -
Distal end portions 44 ofpole pieces 24 in the embodiment described above have a profile defined by relativelystraight wall 54 together withhemispherical wall 56. As described above, this shape, together with the correspondingly semicircular shape ofrecesses 113 provided withingaps 110 betweenadjacent body segments 104 ofstrip 100, allowsdistal end portions 44 ofpole pieces 24 to be received and captured withinrecesses 113 andgaps 110 upon bending deformation ofstrip 104 abouthinge portions 106 betweenadjacent body segments 104. However, the shape ofdistal end portions 44, as well as the corresponding profiles ofgaps 110, may vary. - Referring to
FIGS. 13A and 13B , alternative shapes or profiles for thedistal end portions 44 ofpole pieces 24 and corresponding features instrip 100 are shown. Referring toFIG. 13A , a half-dovetail interface is shown betweenpole piece 24 andstrip 100, in whichdistal end portion 44 ofpole piece 24 includes a half-dovetail projection 170 having a first,distal wall 172 normal to the longitudinal axis ofpole piece 24, an first angled second dovetail or lockingwall 174, and a third, angled lead-inwall 176.Strip 100 includes acorresponding dovetail recess 178 defined byfirst walls 180, a second angled dovetail or lockingwall 182 in afirst body segment 104, and a third, angled lead-inwall 184 in theadjacent body segment 104 ofstrip 100. - As shown in
FIG. 13A , asstrip 100 is wound aboutcarousel 148 in the manner described in detail above with respect to the previous embodiment,body segments 104 ofstrip 100 close abouthinge portions 106 with the third, lead-inwalls first walls second walls 182 ofbody segments 104 closing about and engagingsecond walls 174 ofdistal end portions 44 ofpole pieces 24 to capturedistal end portions 44 ofpole pieces 24 andsecure pole pieces 24 tocore 22. The half-dovetail engagement between angledsecond walls pole pieces 44 andbody segments 104, respectively, firmly lockspole pieces 44 in place betweenbody segments 104 ofstrip 100. - Referring to
FIG. 13B , an alternative half-dovetail interface betweenpole piece 24 andstrip 100 is shown, in whichbody segments 104 ofstrip 100 includeadditional recesses 186 which close aboutshoulder portions 188 ofdistal end portions 44 ofpole pieces 24. In further embodiments, a full dovetail interface may be used betweenpole piece 24 andstrip 100 to provide a still more rigid locking interface between thepole pieces 24 andcore 22. Other types of interlocking interfaces between thepole pieces 24 andcore 22 may be used. - In further embodiments, shown in
FIGS. 16A , 16B, and 17, electrical windings may be wound ontopole pieces 24 prior to loading ofpole pieces 24 intocarousel 148. Referring toFIG. 16A ,electrical windings 190 may be would aboutbobbins 192, which may be made of an insulating material such as a plastic and shaped to fit overpole pieces 24. As shown inFIG. 16B ,bobbins 192 may includerecesses 194 to located the initial winding layer ofwindings 190 and thereby aid in the uniform winding ofwindings 190 aboutbobbins 192. Then, as shown inFIG. 17 ,pole pieces 24 withbobbins 192 may be loaded on tocarousel 148 between pairs of locatingblocks 150, followed by windingstrip 100 aroundpole pieces 24 to formcore 22 ofarticle 20, as described above. In another embodiment, an insulation material (not shown) may be over-molded directly ontopole pieces 24 followed by windingwindings 190 directly ontopole pieces 24 over the insulating layer. In this embodiment, pole pieces are “pre-wound” prior to formation ofarticle 20, which may be advantageous in the event the particular geometry ofcore 22 andpole pieces 24 would make winding ofpole pieces 24 difficult after formation ofarticle 20. - In a further embodiment (not shown)
carousel 148 may be configured such that multiple horizontal levels of sets ofpole pieces 24 may be held bycarousel 148, perhaps with spacer members (not shown) disposed between the individual pole piece layers. This configuration would allow several layers ofpole pieces 24 to be loaded ontocarousel 148 during a common loading operation, withseveral cores 22 formed respectively about the pole piece layers. Between each layer,strip 100 would be cut,carousel 148 would be vertically indexed, andstrip 100 would be sequenced to and wound about a next level ofpole pieces 24 to form anew article 20. In this manner, a number of annularlaminated parts 20 may be formed via a continuous operation without having to remove eachpart 20 andre-load carousel 148 withpole pieces 24 after the formation of each annularlaminated part 20. - Optionally, die
assembly 114 may operate using a strip accumulator device (not shown), such thatstrip 100 is not wound aboutcarousel 148 directly upon exitingdie assembly 114. In such an embodiment,strip 100 is accumulated on the strip accumulator device, such as being wound around a rotary accumulator or being overlapped by a ribbon accumulator, before being would aboutcarousel 148. The use of a strip accumulator device allows dieassembly 114 to operate continuously even whencarousel 148 is not itself operational to receivestrip 100, such as when conducting welding operations on a completedcore 22, during removal of a completedarticle 20 fromcarousel 148, and/or loading ofcarousel 148 withpole pieces 24. - Referring to
FIGS. 14 and 15 , a further advantage of manufacturing annularlaminated articles 20 by the present method involves the ability to selectively tailor and align the grain direction of the metal within a givenlaminated article 20. As shown inFIG. 14 in connection with prior methods in whichannular articles 200 are formed from a stack ofannular laminas 202 that are each stamped as a single, annular piece from a strip of material, the grain of eachannular lamina 202 will be representative of the grain of the strip of material from which thelaminas 202 are stamped. Typically, strips of metal stock material will have a grain direction extending parallel to, and along, the strip itself. Thus, referring toFIG. 14 , the grain direction in any givenlamina 202 will be unidirectional throughout thelamina 202, as illustrated by grain direction arrows GD1. - However, as described in detail above,
laminated articles 20 manufactured via the present method may be manufactured using two or more different die assemblies, and include acore 22 andpole pieces 24 which may be formed from different strips of stock material. Referring toFIG. 15 , if the strips of stock material from whichcore 22 andpole pieces 24 are formed each have a grain direction extending parallel to, and along, the strips of stock material, thecore 22 andpole pieces 24 of the resultingarticle 20 will have differing grain directions. In particular, thepole pieces 24 will have grain directions extending along arrows GD2 along the longitudinal axes ofpole pieces 24 and which, in the resultingarticle 20, will each extend radially similar to the spokes of a wheel.Body segments 104 ofcore 22 will have grain directions extending along arrows GD3 generally parallel to the interior and exterior edges ofbody segments 104 such thatcore 22 will have a grain direction resulting from itscombined body segments 104 that extends around the annular periphery ofcore 22 and approximates a circle with respect to a given layer ofcore 22, or a helix with respect to the multiple layers ofcore 22. However, use of strips of stock material having differing grain directions and/orstamping pole pieces 24 in selected differing orientations with respect to the grain direction of the strip of stock material from whichpole pieces 24 are stamped allows the grain directions within any given article to be selectively tailored to in turn tailor and/or enhance the magnetic properties of the article. - While this invention has been described as having an exemplary design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
Claims (9)
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US13/212,529 US8786158B2 (en) | 2010-08-19 | 2011-08-18 | Continuously formed annular laminated article and method for its manufacture |
US14/304,417 US9479034B2 (en) | 2010-08-19 | 2014-06-13 | Continuously formed annular laminated article and method for its manufacture |
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US9479034B2 (en) | 2016-10-25 |
US20120043848A1 (en) | 2012-02-23 |
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